Magnetic head with adaptive data island and mini-outrigger and methods of manufacture

ABSTRACT

In one aspect, an exemplary method of manufacturing a magnetic head assembly is provided. In one example, the method includes forming islands in a magnetic head structure to define a pair of mini-outriggers adjacent a data island, where the data island is separated from each mini-outrigger by a void, and a width of the data island along a direction of tape transport is greater than a width of the mini-outrigger. The method further includes lapping the head structure to remove a portion of the mini-outrigger, thereby creating a wrap angle between the tape and the surface of the data island. In one example, the lapping process reduces the mini-outrigger height relative to the data island in an adaptive manner, where the final contour and height of the mini-outrigger is influenced by the data island surface, e.g., by the width, radius of curvature, and the like.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to magnetic tape read and/orwrite heads, and more particularly to magnetic tape read and/or writeheads having mini-outriggers adjacent active data islands.

2. Description of the Related Art

Magnetic tape continues to be an efficient and effective medium for datastorage in computer systems. Increased data storage capacity andretrieval performance is desired of all commercially viable mass storagedevices and media. In the case of linear tape recording, a popular trendis toward multi head, multi-channel fixed head structures with narrowedrecording gaps and data track widths so that many linear data tracks maybe achieved on a tape medium of a predetermined width, such as one-halfinch width tape. To increase the storage density and reduce access timeof magnetic tapes, data tracks on the tape are arranged with greaterdensity and the tape is streamed by a tape head at increasingly fasterrates.

Magnetic tape heads typically include an active device region withembedded transducers across which the magnetic tape advances. The datatransducers are included on raised strips or ridges, commonly referredto as data islands or bumps, which provide a raised tape support or wearsurface for which the magnetic tape wraps around during use. In otherexamples where the tape is flown over the head structure, datatransducers may be included on a contoured head surface havingaerodynamic bleed slots or the like, which cause the tape separation tobe reduced over the data transducers.

FIG. 7 illustrates an exemplary multi-bump head 720 having three dataislands 724 and two outriggers 726. Data islands 724 include one or moredata transducers. The data transducers may include recording elementsfor writing information onto a magnetic tape and/or reproducing elementsfor reading information from a magnetic tape. An embedded recordingelement produces a magnetic field in the vicinity of a small gap in thecore of the element, which causes information to be stored on magnetictape as it moves across the support surface. In contrast, a reproducingelement detects a magnetic field from the surface of magnetic tape asthe tape moves over the support surface. Typically, the center island724 will include write elements and the outer islands 724 include readelements to perform read-write functions in both directions as is knownin the art. Modern heads generally utilize photolithography and MR headtechnology, able to deposit a combination read and write elements on thesame island, where typically only two bumps are needed for forward andreverse operation.

Additionally, conventional heads may be provided with “outrigger”islands on both sides of the head which help support the tape andcontrol the wrap angle of the tape with the island therebetween.Outriggers, e.g., outriggers 726, are generally similar in size andshape to islands 724. Exemplary head configurations, including dataislands and outriggers, are described in U.S. Pat. No. 4,809,110, whichis hereby incorporated by reference in its entirety as if fully setforth herein.

Generally, there is a microscopic separation between an active deviceregion of the tape head, including recording and reproducing elements,and the tape during operation that reduces the strength of the magneticfield coupled to the tape surface during the recording process. Thesmall separation reduces the coupling between the tape field and thereproducing element, causing a signal loss. This reduction in magneticfield strength is generally referred to as a “spacing loss.” Themagnetic field strength detected by a tape or a reproducing element isproportional to e^(−kd/λ), where d is the head-to-tape separation, λ isthe recording wavelength, and k is a constant. The detected magneticfield strength decreases exponentially both with respect to separationbetween the tape and the support surface and with respect to recordingdensity (which is inversely related to the recording wavelength). Thus,while a limited amount of head-to-tape separation might be acceptable atlow recording densities (100-200 KFCI), smaller transducers used withmagnetic tapes of higher recording densities (over 200 KFCI) cantolerate little to no head-to-tape separation.

Further, to allow for faster access and write times, the media may beadvanced by a head at speeds ranging from 100 to 1,000 inches per secondor more. Increased media speed, however, may entrap air between asupport surface of the head and media. Improper contour at one extrememay allow the air to cause separation or at the other extreme it couldresult in excessive high contact pressure between the media and thesupport surface leading to signal loss and/or excessive damage to themedia.

The amount of head-to-tape separation may be reduced by adjusting thewrap angle of the tape around the head structures (e.g., the outriggersand the islands) to create tension in the tape and reduce the amount ofair that may become entrapped. However, increased tension may cause anincrease in the contact pressure between the tape and head that maydamage the media and/or the head. One method to reduce pressure includesreducing the wrap angle according to the principles described in U.S.Pat. No. 4,809,110, entitled NARROW CONTOUR HEAD ASSEMBLY. The '110patent describes, for example, that if the wrap angle is too large, abubble or arc may occur, creating a separation between the tape and thehead structure. Further, if the wrap angle is too small the tape mayentrap air as it advances over the head structure and increases theseparation therebetween. Accordingly, high-speed tape drive systems aregenerally designed with precise tape paths and contoured tape heads toachieve a desired wrap angle. Manufacturing contoured tape heads withdesired wrap angles is generally costly and complicated.

Increased tension in the tape and resulting pressure between the storagemedia and the head to prevent spacing loss has several deleteriousconsequences to both the storage media and the head. For example,increased tension and pressure may reduce tape life and increase thepossibility of tape damage and data loss. Tape damage may lead toincreased lateral tape motion and decreased reliability. Increasedtension and pressure may also cause the head structure and tape to wearmore quickly resulting in shortened tape and head life.

What is desired is a read/write head structure that presents anappropriate wrap angle to the magnetic tape to decrease spacing lossbetween the active device regions and the magnetic tape and reducepressure (and resulting wear) between the magnetic tape and the headstructure. Further, a head structure with reduced manufacturingcomplexity and cost is desired.

BRIEF SUMMARY OF THE INVENTION

In one aspect, an exemplary method of manufacturing a magnetic headassembly with a desired wrap angle is provided. In one example, themethod includes forming islands in a magnetic head structure to define apair of mini-outriggers adjacent a data island, where the data island isseparated from each mini-outrigger by a void, and a width of the dataisland along a direction of tape transport is greater than a width ofthe mini-outriggers. The method further includes lapping the headstructure to remove a portion of the mini-outrigger, thereby creating awrap angle between the tape and the surface of the data island. In oneexample, the lapping process reduces the mini-outrigger height relativeto the data island in an adaptive manner, where the final contour andheight of the mini-outriggers are influenced by the data island surface,e.g., by the width, radius of curvature, and the like.

In another aspect, an exemplary magnetic head assembly for writingand/or reading from magnetic recording media is provided. In oneexample, a magnetic head includes a data island associated with at leastone data transducer, the data island having a width along a direction ofmedia transport and a radius of curvature. The magnetic head furtherincluding a pair of mini-outriggers placed adjacent to the data islandand separated by a void, wherein a width of each of the mini-outriggersalong the direction of media transport is less than the width of thedata island. In one example, the radius of curvature of each of themini-outriggers varies. Additionally, in one example, the radius ofcurvature of the mini-outriggers is less than the radius of curvature ofthe data island. The wrap angle of magnetic storage tape to the dataisland may be less than 3 degrees. Further, the radius of curvature ofthe mini-outrigger may be less than one-half the radius of curvature ofthe data island.

Various aspects and examples of the present invention are betterunderstood upon consideration of the detailed description below inconjunction with the accompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of an exemplary head structureincluding paired data islands having mini-outriggers and primaryoutriggers;

FIGS. 2A and 2B illustrate a plan view and side view of an exemplaryhead structure including data islands having mini-outriggers;

FIGS. 3A and 3B illustrate an exemplary data island and mini-outriggerin greater detail;

FIGS. 4A-4D illustrate an exemplary method for lapping a head structureincluding a data island and a pair of mini-outriggers;

FIG. 5 illustrates another exemplary head including a singlemini-outrigger;

FIG. 6 illustrates another exemplary head including a mini-outriggeradjacent a primary outrigger; and

FIG. 7 illustrates a magnetic head structure including islands andoutriggers.

DETAILED DESCRIPTION OF THE INVENTION

Various exemplary head structures and methods of manufacturing magneticread and/or write heads are provided. The following description ispresented to enable any person of ordinary skill in the art to make anduse various aspects of the invention. Descriptions of specificmaterials, techniques, and applications are provided only as examples.Various modifications to the examples described herein will be readilyapparent to those skilled in the art, and the general principles definedherein may be applied to other examples and applications withoutdeparting from the spirit and scope of the invention. Thus, the presentinvention is not intended to be limited to the examples described andshown, but is to be accorded the scope consistent with the appendedclaims.

In one aspect, an exemplary magnetic head assembly may provide reducedpressure per unit area and reduced magnetic tape and head wear bycontrolling the wrap angle between the magnetic tape and portions of themagnetic head structure, e.g., a data island or bump of the headstructure, through the use of mini-outriggers adjacent the data island.The wrap angle is generally the angle established between a tangentplane to the radius of a data island and a plane between the edge andthe adjacent support structure of an island (active or not). The wrapangle may also be considered as the angle from the center of radius ofcurvature of the island across an arc formed by the supporting surfaceof the island as described, for example, in U.S. Pat. No. 4,809,110,which is incorporated herein by reference in its entirety.

In one example, a magnetic head design includes as a support, closelyformed mini-outriggers located at the leading and/or trailing edge of adata island. The mini-outriggers provide a support surface relative tothe larger surface that determines a wrap angle of the tape to thelarger surface. The vertical height and radius of the mini-outriggersrelative to the active data island is adaptive and adjusts duringmanufacturing based on characteristics of data island surface. Forexample, during lapping, the relative height of the mini-outriggers tothe main surface of the data island will be reduced. The radius of thedata island will influence the wear of the mini-outriggers resulting ina height and radius of the mini-outriggers suited for the wrap angle ofthe data island. In particular, the radius/wrap angle of the centerisland may determine the radius/wrap angle of the mini-outriggers afterlapping, e.g., the mini-outriggers adjust or wear to effect a desirablewrap angle to the data island and the mini-outriggers. In one example, alapping tape having properties (e.g., thickness, stiffness, tensions,etc.) similar to that of storage tape may be used and the head lappeduntil the wrap angle converges to a desired value. In other examples,lapping may be timed to cease when the wrap angle matches a desiredvalue.

In one example, the head may be manufactured by removing material from amonolithic structure through standard machining processes to define adata island(s) and mini-outrigger(s). The material hardness, contour,and width of the data islands and mini-outriggers determine, at least inpart, the wear characteristics of each. In order to decrease therelative height of the mini-outriggers to the data island and create adesired wrap angle between the tape and the supporting surface of thedata island, the mini-outrigger width is selected to be narrower thanthe data island. Lapping is well known in the art for conditioning andmanufacturing tape heads and lapping may be used to condition the head,where conditioning the head includes wearing the mini-outriggersaccording to the main data island surface. In one example, the headstructure is lapped and the mini-outrigger wears to a height and havinga radius of curvature that provides a desired wrap angle of the tape tothe surface of the data island. In another example, the wear of themini-outrigger, based at least in part on the width and contour of thedata island, will create an optimum or nearly optimum relative heightand contour of the mini-outrigger to the main data island.

The exemplary methods may be used to create a wrap angle to the maindata island support surface to within a fraction of a degree, and in oneexample, within ±0.1 degrees of a desired wrap angle. In one example,the mini-outriggers are lapped during manufacturing such that the wrapangle of the tape to the data islands from the mini-outriggers is lessthan 3 degrees, in another example less than 0.5 degrees, and in yetanother example, 0.2 degrees or less.

The exemplary head assembly may be manufactured at reduced cost andcomplexity and with greater precision than conventional head structures.For example, conventional contoured head structures are generallymanufactured with complex contours to create precise wrap angles withindesired tolerances. The complexity to create a conventional contouredhead structure with a desired wrap angle comes at a significant cost. Incontrast, an exemplary head structure as described below, which mayinclude flat or contoured support surfaces, may be advantageouslymanufactured through standard processes to create a desired wrap angleby removing material from the head assembly to define mini-outriggersadjacent the data island(s); for example, using conventional processesfor forming islands such as machining, etching, or the like. The maximumdepth of material removed in forming the mini-outriggers is generallynot critical and typically is a function of the manufacturing process.In one example, the minimum depth is selected to be sufficient tocontinue to provide a desired wrap angle after the surface has been worndown to its final state. The final contour forming of the supportstructures is according to known lapping processes to create a desiredheight of the mini-outrigger and resulting wrap angle with the dataisland. The wear on the mini-outriggers depends, at least in part, onthe width and radius of curvature of the data island.

Exemplary head assemblies are described as being particularly useful aspart of a linear tape head assembly for use in a magnetic tape headassembly with transducer elements that may include suitable read/writeelements, such as magneto resistive read/write elements (often referredto as “MR” heads or elements). Those skilled in the art, however, willunderstand that the transducer element or core may be a core inductivehead, a ferrite core, a thin film gap head, or other type of transducerin which it is useful to provide desired wrap angles to reduce pressureand wear between the storage media and support surfaces of the head.

FIG. 1 illustrates a perspective view of an exemplary magnetic tape head20 including active data islands 24 having mini-outriggers (not shown).Magnetic tape head 20 is illustrated as a paired head assembly, whereina given section of the tape is first written upon by a write element andthereafter checked by a read element. A tape 30 is drawn over thesurfaces of islands 24, which include active device regions (not shown)having one or more data transducers, e.g., read or write elements.Additionally, tape 30 is drawn over primary outriggers 26. Active deviceregions may include, for example, a column of 16 write transducers and acolumn of 16 read transducers.

An exemplary magnetic tape 30 is illustrated in FIG. 1 advancing acrossthe support surface 22 of magnetic tape head 20. Further, an arrow shownon tape 30 indicates the reversible direction of tape 30 movementrelative to magnetic tape head 20, and an arrow shown on head 20indicates the relative movement of head 20 to the path of tape 30 in adirection generally orthogonal to the direction of tape 30 advancement.The movement of magnetic tape head 20 allows head 20 to align readand/or write transducers in the active regions to read and/or writeinformation along one or more different data tracks arrangedlongitudinally along tape 30; for example, a suitable servo system maysend position signals to a controller which in turn controls an actuatorfor translating head 20 relative to tape 30.

Exemplary tape drive systems that may include an exemplary headdescribed herein are disclosed in U.S. Pat. No. 6,188,532, entitled“BACKWARD COMPATIBLE HEAD AND HEAD POSITIONING ASSEMBLY FOR A LINEARDIGITAL TAPE DRIVE,” and U.S. Pat. No. 6,369,982, entitled “FLOATINGTAPE HEAD HAVING SIDE WINGS FOR LONGITUDINAL AND AZIMUTH PLAY BACK WITHMINIMIZED TAPE WRAP ANGLE,” both of which are incorporated by referenceherein in their entirety.

With reference to FIGS. 2A and 2B, a more detailed view of exemplarythin film head structure 20 is illustrated. In particular, FIG. 2Aillustrates a top view of supporting surface 22 of head 20 includingprimary outriggers 26 and data islands 24 including active device region52, and mini-outriggers 42. Mini-outriggers 42 are separated from island24 by a void or separation 25 and primary outriggers 26 are separatedfrom data islands 24 and mini-outriggers 42 by a void or separation 27.FIG. 2B illustrates a side view of head 20 and magnetic storage tape 30passing over primary outriggers 26 and data islands 24.

Tension is applied to tape 30 as tape 30 advances across head 20 andresults in tape 30 exerting a pressure against head 20. In particular,pressure is exerted against support surfaces of data islands 24,mini-outriggers 42, and primary outriggers 26. The pressure is generallyuniform along the direction transverse to the direction of advancementof tape 30. The pressure is generally proportional to the tension andthe wrap angle to the particular surface, and inversely proportional tothe width of the particular support surface. The pressure on islands 24may be altered, for example, by modifying the tension in the tape, bymodifying the wrap angle of the tape with islands 24, or by modifyingthe width (along the direction of tape advancement) of the supportsurface of islands 24. In particular, the local pressure on the surfaceof tape 30 is generally increased by increasing the tension in tape 30,by increasing the wrap angle of tape 30 on islands 24, or by decreasingthe width of the support surface. Generally, decreased pressure betweenthe storage tape 30 and data islands 24 results in an increase in lifeof the storage tape 30 and head 20. Accordingly, by decreasing the wrapangle between the plane of tape 30 as it approaches data island 24 andthe surface of data island 24, pressure between tape 30 and data island24 will decrease.

Magnetic head 20 includes mini-outriggers 42 formed on opposite sides ofan active data island 24, e.g., trailing and leading island 24. Thevertical height and horizontal separation (as seen in FIG. 2B) ofmini-outriggers 42 from island 24 are such that a desired wrap angle oftape 30 to the supporting surface of data island 24 is achieved. Inparticular, the wrap angle, e.g., the angle at which the plane of thesupport surface of island 24 and a plane of magnetic tape 30 interact,may be varied by varying the position, width, and height ofmini-outriggers 42. In one exemplary manufacturing method, structures ofhead 20 are defined from a monolithic material or composite material bymachining to form data islands 24 and outriggers 26 and 42. Thestructure is then lapped to reduce the height of mini-outriggers 42 andcreate a desired wrap angle to islands 24. The width of mini-outriggers42 is less than the data island 24 surface and will therefore be removedduring lapping at a greater rate than the data island 24 surface.

In one example, data island 24 is substantially unchanged during thelapping, i.e., very little material is removed from the surface.Therefore, a wrap angle may be preselected or predetermined according tothe width and contour, e.g., radius of curvature or the like, of dataisland 24 and the width and position of mini-outrigger 42. During alapping process, e.g., with a given amount of time, pressure, etc., alapping tape will wear and remove material from mini-outrigger 42 suchthat the vertical height is stepped with respect to island 24 and theradius of curvature of mini-outrigger 42 is reduced. Further, in someexamples each mini-outrigger 42, on opposing sides of island 24, mayhave different curvatures and/or heights relative to the support surfaceof island 24. For example, as mini-outriggers 42 are worn and adaptduring lapping the height and curvature of each mini-outrigger 42 mayvary.

In this example, head 20 further includes primary outriggers 26, oftenreferred to as inactive islands or bumps. Primary outriggers 26 may beincluded and configured to provide a desired wrap angle of tape 30 tothe mini-outriggers 42. Additionally, primary outriggers may serve toclean debris from tape 30 and steady the motion of tape 30 over dataislands 24 as is generally known in the art. In one example, wrap anglesto the primary outriggers are between approximately 2-5 degrees.

The basic principles described are applicable to a wide range ofmini-outrigger sizes and configurations. Generally, the actual head andmanufacturing efficiency determine the upper limit of ratios between theislands and mini-outrigger dimensions. In one example, the width, d_(i),of island 24 is between 0.010 to 0.020 inches, the width, d_(s1), ofseparation between islands 25 and mini-outriggers 42 is approximately0.0040 to 0.08 inches and the support surface width, d_(b), ofmini-outriggers 42 is approximately 0.0040 to 0.08 inches. In contrast,the width, d_(s2), of space 27, between primary outrigger 26 andmini-outrigger 42 is approximately 0.020 to 0.030 inches, and the width,d_(p), of primary outrigger 26 is 0.010 to 0.020 inches.

In one example, the radius of curvature of data island 24 may range from0.30 to 1.00 inches and be off set from vertical by 2 to 3 degrees. Theradius of curvature of mini-outrigger 42 may be approximately 0.0150 to0.250 inches. Accordingly, in one example, the radius of curvature ofmini-outrigger 42 is less than data island 24; in another example, theradius of curvature of mini-outrigger 42 is less than half the radius ofcurvature of data island 24; and in further examples less than one-thirdand less than one-quarter. Additionally, primary outrigger 26 mayinclude a radius of curvature of 0.2 to 0.4 inches and be off set fromvertical by 9 degrees, for example. Depending on the particularapplication and desired wrap angle, however, other widths and ratios arecontemplated for both the width of separation 25, d_(s1), and thesupport surface width, d_(b).

The height of mini-outriggers 42 and data island 24 may vary dependingon the particular application and manufacturing methods. For example,separations 25 and 27 may be merely deep enough to provide sufficientwrap angle (e.g., without air bleeding) or could be deep enough toextend significantly deeper as well as extending through at least aportion of head 20. In one example, the height of mini-outrigger 42extends 0.0050 inches.

FIGS. 3A and 3B illustrate magnified side-views of data island 24 andmini-outriggers 42 to illustrates the wrap angle created by themini-outriggers 42 in greater detail. The support surface of the head inthis example includes a total wrap angle across the head structures ofapproximately 24 degrees (12 degrees for each side). In other examples,the total wrap angle may be approximately 16 degrees, and in yet otherexamples the head could be a nearly flat surface without curvature. Inoperation, tape (not shown) streams across the top surface of dataisland 24 and mini-outrigger 42 creating a wrap angle θ with data island24. The wrap angle is determined roughly by the separation anddifference in height of the tape exit tangent point at the edge of dataisland 24 and the corresponding side of the mini-outrigger 42 as definedby the height and radius of mini-outrigger 42. For example, as shown ingreater detail in FIG. 3B, the height of mini-outrigger 42 is steppedlower than data island 24 as measured along the vertical, and thecontour of the surface of island 24 various from outrigger 42.Accordingly, magnetic media, as supported by mini-outrigger 42,approaches the edge of data island 24 along a plane from the left edgeof mini-outrigger 42 to the right edge of data island 24. The planeforms an angle 0, the wrap angle, with the plane of the surface of dataisland 24. In one example, the wrap angle is less than 3°, in anotherexample less than 1°, and in another example less than 0.5°. The wrapangle, θ, to island 24 may be varied for different applications anddesired effects.

In one example, for a multi-bump head, the radius of curvature of eachdata island “R” approximates the “natural curvature” of the tape.Various aspects of exemplary head configurations, including data islandsand outriggers having a running radius or wrap angle approximating the“natural curvature” of the tape are described, for example, in U.S. Pat.No. 4,809,110, entitled NARROW CONTOUR HEAD ASSEMBLY, which is herebyincorporated by reference in its entirety as if fully set forth herein.Broadly speaking, the “natural curvature” of the tape is the radius ofthe smallest circle the tape can form without breaking, and isdetermined by the inherent stiffness of the tape, N, the tension appliedto the tape, T, and the wrap angle θw, in accordance with the formula:θwRn=2√(N/T).

It will be noted that N, being an inherent property of the tape, ispredetermined. For currently available magnetic tapes N is on the orderof 0.0001 (10⁻⁴), for example. The tension, T, is also constrained byexternal factors such as the power of the drive motors and the tensilestrength of the tape itself. It is generally desirable that T be kept assmall as is consistent with maintaining good contact between the tapeand the head. It has been found that data island with a radius ofcurvature substantially shorter than the natural radius have erraticrecording behavior early in the head life due to lift off of the tapefrom the data island. The data island will wear down rapidly and,because of lift-off, irregularly, creating a large volume of debriswhich tends to stick to the tape causing high error rates. Because ofthe wear-in irregularities, the data island may never attain a smoothsteady-state radius, but may continue to have a significant wear ratethroughout its life. Data islands having a radius of curvaturesubstantially greater than the natural radius of curvature of the tapealso have been found to wear irregularly and cause media failures. Incontrast, data islands having a radius of curvature no less than abouthalf the natural radius have been found to wear in rapidly without muchlift-off to a contour approximating the natural curvature of the tape,and to have negligible wear thereafter. As a result, an extremely longhead life can be expected from the lower wrap angle and the resultantreduction in the pressure between the head and tape. Accordingly, in oneexample, the radius “R” of the data islands is manufactured to beapproximately ½ to ⅔ of the natural radius of curvature of the tape.Additionally, the radius “r” of the mini-outriggers is less than “R;” inone example, ½ of R, and in other examples ⅓ or ¼ of R.

It will be understood, however, that various other factors andconsideration may be taken into account in selecting a desired radius ofcurvature of the data islands, and the above discussion is illustrativeonly of one example. Further, one may find many solutions to the basicequations relating to the natural radius, however, generally it isdesired to reduce the pressure and wear on the tape and head.

FIGS. 4A-4D illustrate an exemplary process for fabricating an exemplaryhead structure including a data island with mini-outriggers. FIG. 4Aillustrates a cross-section of head 420 including a substrate layer 460,device layer 462, and active device 452 formed therein. Substrate layer460 may include any suitable material including, e.g., AlTiC, Zirconia,CaTi, ferrite materials, or the like and device layer 462 may anysuitable material including, e.g., AlTiC, Zirconia, CaTi, ferritematerials, or the like. Active device 452 may include data transducersformed by any suitable method and of any suitable material. For example,conventional deposition and etching techniques and the like may be used.The top surface of device layer 462 is broken by a gap through which themagnetic pattern on the tape interacts with the field surrounding thehead core.

FIG. 4B illustrates the exemplary head structure after processing toform separations 425 and 427 thereby defining data islands 424,mini-outriggers 442, and primary outriggers 426. In one example, amethod of manufacturing the magnetic head includes removing a portion ofthe head structure to define an active data island 424 andmini-outrigger 442 as described above. Any suitable method may be usedfor removing portions of the head structure to form separations 425 and427. For example, machining, laser ablation, dry or wet etches, plasmaetch, or other suitable methods may be employed. Additionally, in otherexamples, selective deposition of materials may create islands 424,mini-outriggers 442, and primary outriggers 426.

Head 420 may include various suitable materials for magnetic storagedevices. Exemplary materials include, but are not limited to, AlTiC,Zirconia, CaTi, ferrite materials, or the like. In one example, head 420includes a monolithic material in which separations 425 and 427 areformed. In other examples, island 424 and mini-outrigger 442 may includedifferent materials having different wear characteristics to achieve adesired wrap angle. For example, island 424 may include material(s)having more or less wear resistance than material(s) included inmini-outriggers 442. Additionally, in this example, active device region452 includes magneto-resistive (MR) elements. Head 420 and MR elementsmay include various suitable materials and configurations known in theart; for example, suitable MR or giant magnetoresistive materials.

After separations 425 and 427 have been formed, a lapping tape is usedto remove portions of the head structure and create a desired wrap angleas shown in FIG. 4C. As discussed above, the positioning and width ofthe mini-outrigger 442 may be adjusted depending on, for example, thematerials, tape speed, and the like to create a predetermined or desiredwrap angle of the tape with island 424. Initially, the wrap angle frommini-outrigger 442 to island 424 is at or near zero, e.g., the height ofmini-outrigger 442 is similar to the surface of island 424 (orconsistent with a radius of curvature of device layer 462). As thelapping tape is streamed across the head, mini-outrigger 442 will wearor depress more than the support surface of island 424 because of thehigher wrap angle to mini-outrigger 442 and thinner support surface ofmini-outrigger. The relative height of mini-outrigger 442 (in thisfigure to the left of island 424) thereby increases the wrap angle ofthe tape with respect to the island 424. In one example, the lappingprocess may be timed to effect a desired wrap angle to a high degree.For example, typically lapping process can effect a desired wrap angleto within ±0.1 degrees.

In one example, a lapping tape including more highly corrosivematerial(s) than typical tape, such as a conventional diamond lappingtape, chromium dioxide, and the like, may be used initially to wear downprimary outrigger 426 and mini-outriggers 442 to create a desired wrapangle with island 424. In one example, the wrap angle between tape andthe edge of the support surface of island 424 is between 1 and 2 degreesor less. Further, the wrap angle between tape and primary outriggers 426is between 3 and 5 degrees. The angles described are relative tohorizontal, however, the drive itself may provide additional wrap angle,e.g., an additional 3 degrees, for a total wrap angle of 12 degrees toeach side of the exemplary head. The wrap angles may depend on theparticular application and design. It should be recognized that otherwrap angles are possible and contemplated. Additionally, secondarylapping tapes may be used for further manufacturing or pre-conditioningof the head structures before use.

FIGS. 5 and 6 illustrate other exemplary head structures 520 and 620.FIG. 5 illustrates an exemplary head 520 including a singlemini-outrigger 542 corresponding to each data island 524. In thisexample, the single mini-outrigger is shown toward the outside of dataisland 524, but in other examples, mini-outriggers may be placed towardthe inside of data island 524. Mini-outrigger 542 may be manufacturedsimilarly to mini-outriggers described above. Additionally, multiplemini-outriggers may be included on either side of data island 524.Additionally, one or more mini-outriggers may be placed adjacent primaryoutrigger 526.

FIG. 6 illustrates an exemplary head 620 including mini-outriggers 648disposed on either side of primary outrigger 626 along a direction oftape transport. In this example, mini-outriggers 648 may provide a moreuniform wrap angle to primary outrigger 626, reduced pressure betweentape and primary outrigger 626, and the like. In other examples,mini-outriggers 648 may be included on a single side of primaryoutrigger 626, for example, on the outside or inside of primaryoutrigger 626.

Those of ordinary skill in the art will recognized that additionaloutriggers and/or mini-outriggers may be included or omitted inexemplary head designs. Also, exemplary heads herein have been describedas paired data islands, but in other examples a head may include one orany number of data islands. For example, a common configuration includesthree data islands having a center write data island and two read dataislands on either side. One or more data islands in any multi-bumpsystem may include one or more mini-outriggers to effect a desired wrapangle. Further, multiple mini-outriggers may be used on each side of adata island.

The above detailed description is provided to illustrate exemplaryembodiments and is not intended to be limiting. It will be apparent tothose skilled in the art that numerous modification and variationswithin the scope of the present invention are possible. For example,various support surface contours and separation widths may be used.Further, numerous other materials and processes not explicitly describedherein may be used within the scope of the exemplary methods andstructures described as will be recognized by those skilled in the art.Accordingly, the present invention is defined by the appended claims andshould not be limited by the description herein. Additionally,particular examples have been discussed and how these examples arethought to address certain disadvantages in related art. This discussionis not meant, however, to restrict the various examples to methodsand/or systems that actually address or solve the disadvantages.

1. A method for manufacturing a magnetic head for use with a magneticstorage medium, comprising: forming islands in a magnetic head structureto define a mini-outrigger adjacent a data island, wherein a supportingsurface of the data island is separated from a supporting surface of themini-outrigger by a void, and a width of the supporting surface of thedata island is greater than a width of the supporting surface of themini-outrigger along a direction of media transport; and lapping themagnetic head structure to remove a portion of the mini-outrigger,thereby creating a wrap angle with the supporting surface of the dataisland.
 2. The method of claim 1, wherein lapping comprises removing theportion of the mini-outrigger while leaving the data island surfacesubstantially unchanged.
 3. The method of claim 1, wherein themini-outrigger adapts to the data island surface contour and width whenlapped.
 4. The method of claim 1, wherein lapping comprises lappingaccording to a known lapping function to remove a predetermined portionof the mini-outrigger surface.
 5. The method of claim 1, wherein formingcomprises etching.
 6. The method of claim 1, wherein forming comprisesmachining.
 7. The method of claim 1, wherein the wrap angle is less than3 degrees.
 8. The method of claim 1, wherein the wrap angle is less than1 degree.
 9. The method of claim 1, wherein the wrap angle is less than0.5 degrees.
 10. The method of claim 1, wherein the data island includesa radius of curvature and the mini-outrigger includes a radius ofcurvature, and the radius of curvature of the mini-outrigger is lessthan the radius of curvature of the data island.
 11. The method of claim10, wherein the radius of curvature of the mini-outrigger is betweenone-third and two-thirds of the radius of curvature of the data island.12. The method of claim 10, wherein the radius of curvature of themini-outrigger is less than one half of the radius of curvature of thedata island.
 13. The method of claim 1, wherein the width of themini-outrigger along the direction of media transport is less than 8milli-inches.
 14. The method of claim 1, wherein the width of the dataisland along the direction of media transport is between 10 and 50milli-inches.
 15. A magnetic head for use with magnetic storage mediamanufactured by the method of claim
 1. 16. A method for manufacturing amagnetic head for use with a magnetic storage medium, comprising:forming islands in a magnetic head structure to define a mini-outriggeradjacent a data island, wherein a supporting surface of the data islandis separated from a supporting surface of the mini-outrigger by a void,a width of the supporting surface of the data island is greater than awidth of the supporting surface of the mini-outrigger along a directionof tape transport, and an initial height of the supporting surface ofthe data island and the supporting surface of the mini-outrigger areequal; and lapping the head structure including the supporting surfaceof the data island and the supporting surface of the mini-outrigger,wherein the lapping removes a greater portion of the mini-outrigger thanthe data island.
 17. The method of claim 16, wherein lapping comprisesremoving the portion of the mini-outrigger while leaving the data islandsurface substantially unchanged.
 18. The method of claim 16, wherein themini-outrigger adapts to the data island surface contour and width whenlapped.
 19. The method of claim 16, wherein lapping comprises lappingaccording to a known lapping function to remove a predetermined portionof the mini-outrigger surface.
 20. The method of claim 16, whereinforming comprises etching.
 21. The method of claim 16, wherein formingcomprises machining.
 22. The method of claim 16, wherein the wrap angleis less than 3 degrees.
 23. The method of claim 16, wherein the wrapangle is less than 1 degree.
 24. The method of claim 16, wherein thewrap angle is less than 0.5 degrees.
 25. The method of claim 16, whereinthe data island includes a radius of curvature and the mini-outriggerincludes a radius of curvature, and the radius of curvature of themini-outrigger is less than the radius of curvature of the data island.26. The method of claim 25, wherein the radius of curvature of themini-outrigger is between one-third and two-thirds of the radius ofcurvature of the data island.
 27. The method of claim 25, wherein theradius of curvature of the mini-outrigger is less than one half of theradius of curvature of the data island.
 28. The method of claim 16,wherein the width of the mini-outrigger along a direction of tapetransport is less than 8 milli-inches.
 29. The method of claim 16,wherein the width of the data island along a direction of tape transportis between 10 and 50 milli-inches.
 30. A magnetic head for use withmagnetic storage media manufactured by the method of claim
 16. 31. Amulti-island magnetic recording head for writing to and/or reading froma magnetic storage medium as it passes thereover, comprising: a firstdata island associated with a first data transducer; and a first pair ofmini-outriggers disposed on opposite sides of the first data islandalong a direction of tape transport, wherein each of the first pair ofmini-outriggers have a different radius of curvature from each other.32. The head of claim 31, further comprising: a second data islandassociated with a second data transducer; and a second set ofmini-outriggers disposed on opposite sides of the second island along adirection of tape transport, wherein each of the second pair ofmini-outriggers have a different radius of curvature from each other.33. The head of claim 32, wherein the radius of curvature of each of thefirst and second pairs of mini-outriggers is less than two-thirds theradius of curvature of the first and second data islands.
 34. The headof claim 31, further comprising primary outriggers disposed at theleading and trailing edge of the head.
 35. The head of claim 31, whereinthe first pair of mini-outriggers effect a wrap angle of magneticstorage tape to the first data island of less than 3 degrees.
 36. Thehead of claim 35, wherein the wrap angle is less than 1 degree.
 37. Thehead of claim 35, wherein the wrap angle is less than 0.5 degrees. 38.The head of claim 35, wherein the first data island and each of thefirst pair of mini-outriggers are separated by approximately 10 to 50milli inches.
 39. The head of claim 35, wherein a width of the firstpair of mini-outriggers along a direction of tape transport is between 3and 8 milli-inches, and a width of the first data island along adirection of tape transport is between 10 and 40 milli-inches.